System and method for perforating paint-roller cover fabric

ABSTRACT

In an embodiment, a paint roller manufacturing system and method uses a fabric-coating applicator to apply a fabric adhesive onto a portion of a perforated paint roller cover fabric material having a plurality of perforations through which adhesive may flow, and into the plurality of perforations and into interstitial spaces of the fabric material, to yield a length of coated fabric. An inner strip and an outer strip are wound about a mandrel in offset relation. A strip-coating applicator is used to apply a strip adhesive to the outer strip as it is wound about the mandrel. Simultaneously with the step of applying the strip adhesive to the outer strip, a portion of the coated paint roller fabric material is received at the outer strip and the length of coated fabric is wound about at least the outer strip to form a paint roller tube.

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/968,476 filed May 1, 2018, which is a continuation of U.S.patent application Ser. No. 15/676,507 filed Aug. 14, 2017, the entiredisclosures of which are incorporated herein by reference.

FIELD

The present invention relates in general to the field of paint rollermanufacturing, and in particular to a novel machine and process forusing a perforated fabric in a process for manufacturing paint rollers.

BRIEF DESCRIPTION OF THE DRAWINGS

Objects, features, and advantages of the invention will be apparent fromthe following description of preferred embodiments as illustrated in theaccompanying drawings, in which reference characters refer to the sameparts throughout the various views. The drawings are not necessarily toscale, emphasis instead being placed upon illustrating principles of theinvention.

FIG. 1 shows a top view illustrating a machine and process formanufacturing paint rollers in accordance with an embodiment wherein asingle extruder is used to feed two applicators in a two-strip process.

FIG. 2 shows a top view illustrating a machine and process formanufacturing paint rollers in accordance with an embodiment wherein adiversion device is used to direct flow of molten material to twoapplicators in a two-strip process.

FIG. 3 shows a top view illustrating a machine and process formanufacturing paint rollers in accordance with an embodiment wherein twoseparate extruders are used to feed two respective applicators in atwo-strip process.

FIG. 4 shows a top view illustrating a machine and process formanufacturing paint rollers in accordance with an embodiment wherein asingle extruder is used to feed two applicators in a single-stripprocess.

FIG. 5 shows a top view illustrating a machine and process formanufacturing paint rollers in accordance with an embodiment wherein adiversion device is used to direct flow of molten material to twoapplicators in a single-strip process.

FIG. 6 shows a top view illustrating a machine and process formanufacturing paint rollers in accordance with an embodiment of theinvention wherein two separate extruders are used to feed two respectiveapplicators in a single-strip process.

DETAILED DESCRIPTION

Reference will now be made in detail to the preferred embodiments of thepresent invention, examples of which are illustrated in the accompanyingdrawings. The following description and drawings are illustrative andare not to be construed as limiting. Numerous specific details aredescribed to provide a thorough understanding. However, in certaininstances, well-known or conventional details are not described in orderto avoid obscuring the description. References to one or an embodimentin the present disclosure are not necessarily references to the sameembodiment; and, such references mean at least one.

The machine and process may be configured to use a fabric cover that hasbeen pre-perforated offline at a separate facility from the paint rollermanufacturing facility, or can be configured to perforate the fabricinline with the paint roller manufacturing process. With reference toFIG. 1, a paint roller manufacturing system 101 and process formanufacturing paint rollers in accordance with an embodiment areillustrated. The paint roller manufacturing system 101 includes a coverdispenser 122 continuously dispenses a windable width of paint rollercover fabric, the paint roller cover fabric having a back side and anapplicator side. A fabric supporting and advancing device 124 may beprovided to support the fabric and maintaining a width-wise dimension ofthe paint roller cover fabric as the fabric advances, back side up,across the fabric supporting device.

A fabric coating applicator 113 is configured to apply a coating to theback of the paint roller cover fabric. The fabric coating applicator maybe part of a machine at a separate facility from the paint rollermanufacturing facility or may be associated with the paint rollermanufacturing machine and process, as shown. The fabric coatingapplicator is positioned to apply the coating to the back of the paintroller cover fabric while the fabric is supported by the fabricsupporting and advancing device 124. It should be noted that the coatingis applied to the back of the fabric, whether the fabric already has abacking or whether the present process creates a backing by virtue ofapplying a coating to the back of uncoated fabric. The fabric coatingapplicator may be configured to apply a contiguous or non-contiguouscoat of material to the paint roller cover material. Examples of anon-contiguous coat include, without limitation, stripes of coatingmaterial. In addition, the fabric coating application may be configuredto apply additional material, such as a mesh material, to the fabricback side, in addition to a coating material. In an embodiment, a meshmaterial and a contiguous coat of material are applied to the paintroller cover material by the fabric coating applicator. In anembodiment, a mesh material and a non-contiguous coat of material areapplied to the paint roller cover material by the fabric coatingapplicator. A compressing roller 126 is positioned downstream of thefabric coating applicator and configured to apply a compressive force onthe coating after it has been applied to the back side of the paintroller cover fabric. In an embodiment, the compressing roller 126 ispositioned to provide the compressive force upon the coating while thefabric is supported by the fabric supporting and advancing device. In anembodiment, the compressing roller 126 is positioned to provide thecompressive force upon the coating downstream of the location where thefabric is supported by the fabric supporting and advancing device. In anembodiment, the fabric supporting and advancing device 124 is inclineddownward toward the compressing roller 126 at an angle of, e.g., 45degrees. In an embodiment, the angle of the fabric supporting device 124is between 30 and 60 degrees. In an embodiment, the angle of the fabricsupporting device 124 is between 20 and 80 degrees. In an embodiment,the fabric supporting and advancing device 124 is inclined upward towardthe compressing roller 126. In an embodiment, the compressing roller 126is configured with the aid of one or more additional rollers or surfaces(not shown) to provide the compressive force upon the coating downstreamof the area where the fabric is supported by the fabric supporting andadvancing device. In an embodiment, a belt (not shown) between two ormore rollers can be used as such a surface (in this case, a curvedsurface), as an aid to the compressing roller, permitting thecompressive force to be applied across a larger portion of thecompressing roller 126.

A mandrel 121 is provided, and may be cooled by a mandrel cooler 133 soas to facilitate movement of strips around the mandrel in a helicalmanner without adhesion of the strips to the mandrel and with lowerresistance.

First and second strip dispensers 116, 118 are configured tocontinuously dispense first and second windable widths of strip material117, 119. A guide system (not shown) may be used to guide the first andsecond strip coming from the first and second strip dispensers such thatit is wound about the mandrel and to guide the coated paint roller coverfabric from the fabric supporting device to be wound about the first andsecond strips 117, 119. The second strip 119 and/or the first strip 117may be a solid strip, a perforated strip or an embossed strip (e.g.,having recessed dimples).

An adhesive applicator 115 is configured to apply adhesive (which may beglue, a polymer, or a compound polymer) on substantially all of theouter side of the first and second windable strips 117, 119 upstream ofa location where the coated paint roller cover fabric 125 is wound aboutthe first and second strips.

A compressing and advancing device 129 is provided for applying inwardpressure normal to the mandrel on the coated paint roller fabric cover125 after it is wound about the first and second strips 117, 119, andfor advancing the first and second windable strips and the coated paintroller fabric cover along the mandrel 121.

In an embodiment, the machine includes an extruder 103, which may beconfigured for extrusion of an adhesive material through a Y-Adapter105. In an embodiment, the material is molten when it is extrudedthrough the Y-Adapter 105. In an embodiment, the molten material ispushed through hoses 109 and 111 to the fabric-coating applicator 113and the strip-coating adhesive applicator 115, respectively. Thefabric-coating applicator 113 and/or the strip-coating applicator 115may comprise any device for applying liquid adhesive to a fabric,including a die head, sprayer, brush, extruder, or the like.

The inner strip 117 and outer strip 119 of material are helically woundabout the mandrel 121 in offset relation. In an embodiment, the offsetrelation is approximately 50%, that is, that the center of one stripwraps at a location under or over (as the case may be) the middle of theother strip. In an embodiment, the offset relation is at least 5% toprevent the seams of the inner strip and the outer strip from aligning.A 5% offset relation refers to having the seam at least 5% of the widthof the strip away from the edge of the strip. In an embodiment, theentire inner surface of the inner strip 117 contacts the mandrel 121. Inan embodiment, no portion of the outer strip 119 contacts the mandrel121.

The inner strip 117 and the outer strip 119 may comprise any materialthat is flexible so as to be helically wound about the mandrel. In anembodiment, the strips comprise polypropylene. In an embodiment, thestrips comprise a compound of polypropylene and calcium carbonate. Avariety of formulations for strips may be found, e.g., in Applicant'sU.S. patent application Ser. No. 14/789,723 filed Jul. 1, 2015 and thereferences cited therein, the entire disclosures of which areincorporated herein by reference. The resin that is extruded onto thefabric may comprise, for example, (1) commonly-available polypropylene,(2) a blend of polypropylene, with an effective Melt Flow Rate (MFR) of20-140 g/10 min., (3) a combination of Calcium Carbonate (CaCO3) andPolypropylene, with CaCO3 ranges used from 10-66% CaCO3, or (4) acombination of Calcium Carbonate and blend of polypropylene (having ahigh MFR ranging from 700-1400 g/10 min), with CaCO3 ranges from 10-66%CaCO3 by weight, for an effective total MFR of 20-140 g/10 min.

In an embodiment, the outer surface of the inner strip 117 and the outersurface of the outer strip 119 are coated with adhesive by thestrip-coating applicator 115. In an embodiment (not shown), thestrip-coating applicator 115 comprises two separate strip-coatingapplicators, one to coat each of the two strips 117, 119. Thus, suchcoating of the outside of each of the two strips may be performed by thesame applicator or, in another embodiment, by two separate applicators.As shown in FIG. 1, coating of the strip or strips is performed by asingle applicator. In an embodiment, only the outer surface of the innerstrip 117 is coated with adhesive by the strip-coating applicator 115.In an embodiment, the strip-coating applicator 115 applies adhesive toeither the outer surface of the inner strip or the inner surface of theouter strip such that the adhesive ends out between the inner and outerstrips after it is applied. In an embodiment, the strip-coatingapplicator 115 applies adhesive to either the outer surface of the innerstrip or the inner surface of the outer strip such that the adhesiveends out between the inner and outer strips after it is applied, and theliquid adhesive applied by the fabric coating applicator 113 is not setwhen the outer strip 119 and the coated fabric cover 125 come togetheron the mandrel. In an embodiment, the strip-coating applicator 115applies adhesive to either the outer surface of the outer strip or theinner surface of the coated fabric 125 such that the adhesive ends outbetween the outer strip and coated fabric after it is applied. In anembodiment, a portion of the outer surface (rather than the entire outersurface) of the outer strip 119 (or the only strip in a single-stripembodiment) is coated. In an embodiment, the entire outer surface of theouter strip 119 is coated. The strip-coating applicator 115, in eachcase, may be configured to apply a contiguous or non-contiguous coat ofmaterial to the strip. Examples of a non-contiguous coat include,without limitation, a mesh of material, stripes of coating material. Inaddition, the strip-coating application may be configured to applyadditional material, such as a mesh material in addition to a coatingmaterial. In an embodiment, a mesh material and a contiguous coat ofmaterial are applied by the strip coating applicator 115. In anembodiment, the mesh material is a resin mesh. In an embodiment, only aportion of the outer surface of the inner strip 117 is coated. In anembodiment, the entire outer surface of the inner strip 117 is coated.

In an embodiment, cover fabric material 123 is fed through a fabricsupporting and advancing device 124. The fabric supporting and advancingdevice 124 may optionally comprise a stretching device such as a tenterframe where the fabric is stretched (by, e.g., a series of successivelywider spaced pins) in the machine direction, and/or the lateraldirection, so as to open up interstitial spaces between fibers of thefabric. The fabric supporting and advancing device 124 may be configuredto maintain a lengthwise and/or a widthwise dimension of the fabric forat least a portion of the time the fabric is supported by the device. Inan embodiment, the lengthwise and/or widthwise dimension of the fabricare stretched dimensions—that is, larger than the fabric's originaldimensions. In an embodiment, the lengthwise and/or widthwise dimensionof the fabric are unstretched dimensions. In an embodiment, the fabricmaterial 123 is then fed under or through the fabric-coating applicator113 where it is coated with fabric adhesive. In an embodiment, fabricmaterial 123 is then fed under or through the fabric-coating applicator113 while one or more of its dimensions are being maintained by thefabric supporting and advancing device 124. In an embodiment, theadhesive is reactive (e.g., thermally reactive) with the cover materialin the sense that an unsupported fabric material would change dimensionupon the adhesive application. In an embodiment, the fabric supportingand advancing device 124 resists that reaction, and maintains the fabricdimensionally. In an embodiment, by resisting the reaction, the fabricsupporting and advancing device 124 permits more adhesive to fill theinterstitial spaces in the fabric. In an embodiment, by resisting thereaction, the fabric supporting and advancing device 124 creates largerinterstitial spaces in the fabric into which adhesive may flow. In anembodiment, the application of adhesive while the fabric isdimensionally maintained (e.g., stretched or unstretched) will permitadditional molten adhesive to enter the fabric pores, and thus lock downpaint roller fabric fibers that are otherwise known to shed, and thus,reduce shedding in a paint roller made by this process.

A perforation roller 140 is configured to make perforations in thefabric and thus create spaces through which adhesive may flow. In anembodiment, the perforation roller 140 comprises a plurality of spacedperforators, which may comprise perforating pins, that can perforate thefabric and thus create spaces (e.g., pores) through which adhesive mayflow. In an embodiment, the perforators are sharp at a distal end (awayfrom the perforation roller) and are configured so that they can extendthrough the backing layer of the fabric. Several factors should beconsidered in order to provide adequate penetration of the adhesive intothe fabric. The thickness of most paint roller fabric backing is roughly0.30″ to 0.50″. In an embodiment, the machine, adhesive, and process aredesigned so that the adhesive penetrates the fabric by that amount, andnot more. It is generally desirable for the resin to pass through thebacking and to help the fibers adhere to the resin and to the rest ofthe fabric backing.

In an embodiment, the perforators on the perforating roller arewider-diameter pins than are typically used for hot perforation. In anembodiment, perforating pins with a diameter of 0.010″ to 0.018″ areused. Perforators having diameters ranging from 0.06″ to 0.08″ may notprovide an adequately large area for resin to penetrate through thefabric backing described above. The pin heads can have shallow or deeptapers, but the perforating diameter should preferably remain the same.In an embodiment, the pins are located 0.12″-0.24″ from each otherhorizontally, point-to-point, and 0.16″-0.24″ mm vertically, point topoint.

In an embodiment, the fabric passes under the perforating roller withits backing facing the perforating roller and the fabric is supported bya pressure roller as it is passing under the perforating roller. Thepressure roller can be made from a number of materials, such assilicone, or densely-packed tampico fibers.

In an embodiment, the perforating roller is heated to provide improvedperforation of the fabric backing and processing of the fabric. Thetemperatures most suitable for penetration range from 360 F to 450 F,although the temperature used may depend on the type of fabric beingperforated. Internal resistance heaters can be used, since area heatersmay burn the fibers of the fabric.

In order to ensure that the resin used to coat the back of the fabricsufficiently penetrates the fabric backing and makes contact with thefibers, a free-flowing resin should be used. In an embodiment,compounded polypropylene resins that have effective (final, after anycompounding) melt flow rate (MFR) ranges of 100-400 g/10 min are used.In an embodiment, compounded polypropylene resins that have effectiveMFR ranges of 120-220 g/10 min are used. In an embodiment, compoundedpolypropylene resins that have effective MFR ranges of 130-180 g/10 minare used. It is possible to use lower MFR resins if they are notcompounded with filler material, or higher MFR resins if usingcompounded material with a larger percentage of filler, or with fillersthat greatly increase the viscosity of the compounded resin. Thus, in anembodiment, an uncompounded resin with an effective MFR of 20-140 g/10min is used. In an embodiment, a resin compounded with a largepercentage of filler (greater than 50% by weight) with an effective MFRof 140-400 g/10 min is used. The filler may comprise, e.g., calciumcarbonate.

In an embodiment, the perforators are configured so that they can extendthrough the backing layer of the fabric and create spaces or porestherein. In an embodiment, the spaces or pores created in the backingare generally evenly spaced. In an embodiment, the spaces or porescreated in the backing are generally evenly spaced by between ⅛″ and ¼″on center. In an embodiment, the spaces or pores are of sufficient sizeto permit adhesive to enter and thus lock the paint roller fibers onsetting. In an embodiment, the spaces or pores are between 1/32″ and3/32″ across. In an embodiment, the spaces or pores are at least 1/64″across. In an embodiment, the spaces or pores are no more than 1/16″across. In an embodiment, the spaces or pores are no more than 7/64″across. In an embodiment, the spaces or pores are generally round inshape or generally square in shape or generally triangular in shape. Inan embodiment, the perforation roller 140 engages the fabric as it isbeing dimensionally maintained by the fabric supporting and advancingdevice 124. In an embodiment, the perforation roller 140 comprises aplurality of spaced perforators that do not actually perforate thefabric, but rather, merely push the yarns of the fabric aside and thuscreate spaces through which adhesive may flow. This is especially usefulon knit fabric. In an embodiment, a perforation roller may be providedthat is not part of the fabric supporting and advancing device 124, butis instead, upstream or downstream of it. In an embodiment, theperforation roller is upstream of the fabric-coating applicator 113. Inan embodiment, perforators that are not in roller form are used toperforate or rearrange yarns on the fabric backing (e.g., to createpores) into which adhesive can enter when applied by the fabric-coatingapplicator 113.

In an embodiment, the fabric material 123 is fed under or through thefabric-coating applicator 113 while it continues to be stretched. In anembodiment, a compressive force (e.g., by compressing roller 126) isthereafter applied. In an embodiment, a compressive force (e.g., bycompressing roller 126) is applied before the adhesive has set. In anembodiment, the adhesive used sets by cooling (e.g., a molten polymer)and the compressing roller 126 aids in cooling the adhesive, and thusaids in the setting process. In an embodiment, the compressing roller126 is maintained at a temperature lower than that of the adhesive. Inan embodiment, the compressing roller 126 is cooled to aid in thesetting process. In an embodiment, the compressing roller 126 ismaintained at a temperature at or near that of the adhesive to preventthe compressing roller 126 from causing the adhesive to set, andpermitting the adhesive to continue unset for a longer period during themanufacturing process (e.g., until it makes contact with the outersurface of the outer strip 119. The coated fabric 125 is then wrappedaround the outer surface of the outer strip 119.

In an embodiment, glue may be applied on the back of the cover fabricmaterial 123 as a bonding agent prior to its use in the above-describedprocess. Optionally, glue may be applied on the back of the cover fabricmaterial 123 by the fabric coating applicator 113 as a bonding agent, inaddition to the fabric adhesive applied. In an embodiment, glue may beapplied on the back of the cover fabric material 123 by the fabriccoating applicator 113 as the fabric adhesive. Glue may be applied by ahot melt machine, dripped on the back of the fabric using a slot die, orby any other known application method.

The formed (but potentially still setting) paint roller cover materialtube 127 may be driven by a motorized compressing and advancing device129, which may comprise a belt. The formed paint roller cover materialtube 127 may be advanced to a flyaway saw 131, which cuts the tube intolengths. In an embodiment, the lengths of tube may be further cut intolengths used as a paint roller. In an embodiment, the lengths of tubecut by the flyaway saw 131 or as further cut, are finished prior to useas a paint roller.

In an embodiment, the fabric-coating applicator 113 and thestrip-coating applicator 115 comprise two sheet dies, each having awidth appropriate for coating the subject, as described herein. In anembodiment, the fabric coating applicator has a sheet die sufficient tocover all, or substantially all of the backing of the fabric. In anembodiment, the fabric coating applicator has a sheet die wider than thebacking of the fabric. In an embodiment, the advancing coated fabric 125is trimmed as it advances towards the mandrel to remove excess coating.

In an embodiment, the fabric-coating applicator 113 and thestrip-coating applicator 115 comprise two sheet dies, both being 10.5inches in width. In an embodiment, both dies are between 8 and 13 inchesin width. In an embodiment, the fabric-coating applicator die is 3.5inches in width and the strip-coating applicator die is 10.5 inches inwidth. In an embodiment, the width of the fabric-coating applicator dieis between 2 and 5 inches. In an embodiment, the width of thestrip-coating applicator die is between 8 and 13 inches. In anembodiment, the die of the strip-coating applicator has a 0.040 inchwide die gap, and the die of the fabric-coating applicator has a 0.025inch wide die gap. In an embodiment, the die of the strip-coatingapplicator has a die gap that is between 0.025 and 0.055 inches inwidth. In an embodiment, the die of the fabric-coating applicator has adie gap that is between 0.010 and 0.040 inches in width. In anembodiment used to make mini rollers, the width of the strip-coatingapplicator die is between 3 inches and 4.5 inches, and the width of thefabric strip is between 1 inch and 1.5 inch.

FIG. 2 shows an alternative embodiment of a paint roller manufacturingsystem 201 wherein a diversion device is used to direct flow of moltenmaterial to two applicators. This embodiment operates generally asdescribed above with respect to FIG. 1, except that an extruder 203feeds molten material to a diversion device 205, which in turn directs aportion of the molten material from extruder 203 to hose 109 and aportion of material to hose 111. The diversion device 205 may be a fixedvalve, variable valve, gear pump, Y-adapter, or any other device whichcan split a flow from an extruder between two die heads. In embodimentswhere a variable diversion device is used, it may be manually variableto control the proportion of the molten material fed to hose 109 and theproportion of the molten material fed to tube hose. Alternatively, thediversion device may be a dynamically controlled diversion device thatsets such proportions according to conditions or variables of theprocess. Such conditions and variables include, e.g., temperature,viscosity of the molten material, and the particular compound of theadhesive being used.

In an embodiment, diverted flow rates of the diversion device 205 arecomputationally derived. In an embodiment, downstream diverted flowrates of the diversion device 205 are measured and used to control theamount of diversion into each of the hoses 109, 111.

FIG. 3 shows an alternative embodiment of a paint roller manufacturingsystem 301 wherein dual extruders 303 and 304 are used to supply moltenmaterial to two applicators 113 and 115, respectively, via hoses 109 and111. In this manner, different adhesives or compounds of adhesives maybe used to feed the two applicators, with a cover adhesive being used inextruder 303 and a strip adhesive being used in extruder 304. Thisembodiment otherwise operates in a similar manner as described abovewith reference to FIG. 1.

The methods above are described in the context of a two-strip processfor manufacturing paint rollers. One skilled in the art will recognizethat the same or similar methods can be used in a single-strip process,a three-strip process, or the like without departing from the spirit andscope of the invention.

FIG. 4 shows single-strip embodiments 401 of the two-strip machine andprocess shown in FIG. 1. FIG. 5 shows single-strip embodiments 501 ofthe two-strip machine and process shown in FIG. 2. FIG. 6 showssingle-strip embodiments 601 of the two-strip machine and process shownin FIG. 3. These embodiments generally operate as per the descriptionsof FIGS. 1, 2, and 3 above, except that a single strip 117 is usedinstead of the dual strips 117 and 119. In an embodiment, a mesh layeris applied to the strip 117 before or after adhesive is applied byapplicator 115.

In an embodiment of the two-strip machine and process shown in FIGS. 1,2 and 3 above, a mesh layer may be wound between the inner strip and theouter strip. In an embodiment, a mesh layer may be wound between theouter strip and the coated fabric. In an embodiment, the mesh layer maybe aligned (i.e., not in offset relation) with the strip below it (i.e.,closer to the mandrel). In an embodiment, the mesh layer may be alignedwith the strip above it (i.e., farther from the mandrel). In anembodiment, the mesh layer may be in offset relation to the strip belowit. In an embodiment, the mesh layer may be in offset relation to thestrip above it. In an embodiment, the mesh layer, the inner strip andthe outer strip are each in offset relation to each other.

Advantages of the present invention over the present inventor's priorpatents include, but are not limited to the following. It should benoted that some but not all embodiments of the present invention provideeach of these advantages. The present invention can provide asingle-step in-line process for manufacturing a paint roller usingcoated fabric, rather than a two-step offline process, thereby reducingthe amount of time and waste materials required. Machines operatingaccording to the present invention can be configured to use lessadhesive material. Machines in accordance with the present invention canbe configured to use an adhesive for the cover material which isformulated differently than the adhesive used for the strip material.Machines and processes in accordance with the present invention have thepotential to reduce fabric “shedding,” or at least the potential tocreate a stronger bond between the fabric and the rest of the rollercore, i.e. the strip(s) and the resin used for binding.

Reference in this specification to “an embodiment” or “the embodiment”means that a particular feature, structure, or characteristic describedin connection with the embodiment is included in at least an embodimentof the disclosure. The appearances of the phrase “in an embodiment” invarious places in the specification are not necessarily all referring tothe same embodiment, nor are separate or alternative embodimentsmutually exclusive of other embodiments. Moreover, various features aredescribed which may be exhibited by some embodiments and not by others.Similarly, various requirements are described which may be requirementsfor some embodiments but not other embodiments.

As used herein, and especially within the claims, ordinal terms such asfirst and second are not intended, in and of themselves, to implysequence, time or uniqueness, but rather are used to distinguish oneclaimed construct from another. In some uses where the context dictates,these terms may imply that the first and second are unique. For example,where an event occurs at a first time, and another event occurs at asecond time, there is no intended implication that the first time occursbefore the second time. However, where the further limitation that thesecond time is after the first time is presented in the claim, thecontext would require reading the first time and the second time to beunique times. Similarly, where the context so dictates or permits,ordinal terms are intended to be broadly construed so that the twoidentified claim constructs can be of the same characteristic or ofdifferent characteristic.

The above embodiments and preferences are illustrative of the presentinvention. It is neither necessary, nor intended for this patent tooutline or define every possible combination or embodiment. The inventorhas disclosed sufficient information to permit one skilled in the art topractice at least one embodiment of the invention. The above descriptionand drawings are merely illustrative of the present invention and thatchanges in components, structure and procedure are possible withoutdeparting from the scope of the present invention as defined in thefollowing claims. For example, elements and/or steps described aboveand/or in the following claims in a particular order may be practiced ina different order without departing from the invention. Thus, while theinvention has been particularly shown and described with reference toembodiments thereof, it will be understood by those skilled in the artthat various changes in form and details may be made therein withoutdeparting from the spirit and scope of the invention.

1. A method for using a perforated fabric in a paint rollermanufacturing process, comprising: perforating a paint roller coverfabric material with a heated perforator to produce a perforated paintroller cover fabric material; using a fabric-coating applicator to applya fabric adhesive onto a portion of the perforated paint roller coverfabric material having a plurality of perforations through whichadhesive may flow, and into the plurality of perforations and intointerstitial spaces of the fabric material, to yield a length of coatedfabric; winding an inner strip and an outer strip about a mandrel inoffset relation; using a strip-coating applicator to apply a stripadhesive to at least a portion of the outer strip as it is wound aboutthe mandrel; simultaneously with the step of applying the strip adhesiveto the outer strip, receiving a portion of the coated paint rollerfabric material at the outer strip and winding the length of coatedfabric about at least the outer strip to form a paint roller tube;applying compression to the paint roller tube; and, cutting the paintroller tube into like lengths.
 2. (canceled)
 3. (canceled)
 4. (canceled)5. The method for using a perforated fabric in a paint rollermanufacturing process according to claim 1, wherein the heatedperforator comprises a perforating roller.
 6. The method for using aperforated fabric in a paint roller manufacturing process according toclaim 5, wherein the perforating roller comprises a plurality of heatedperforating pins.
 7. The method for using a perforated fabric in a paintroller manufacturing process according to claim 6, wherein the pluralityof heated perforating pins each have a diameter that is at least 0.010inch and not more than 0.018 inch.
 8. The method for using a perforatedfabric in a paint roller manufacturing process according to claim 5,wherein at least a portion of the perforating roller is heated to atemperature that is at least 360 F and not more than 450 F.
 9. Themethod for using a perforated fabric in a paint roller manufacturingprocess according to claim 5, wherein at least a portion of theperforating roller is heated by an internal resistance heater.
 10. Themethod for using a perforated fabric in a paint roller manufacturingprocess according to claim 6, wherein the perforating pins are locatedat least 0.12 inches and not more than 0.24 inches from each otherhorizontally, point-to-point.
 11. The method for using a perforatedfabric in a paint roller manufacturing process according to claim 6,wherein the perforating pins are located at least 0.16 inches and notmore than 0.24 inches from each other vertically, point-to-point. 12.The method for using a perforated fabric in a paint roller manufacturingprocess according to claim 1, wherein the fabric adhesive comprises aresin having polypropylene compounded with a filler.
 13. The method forusing a perforated fabric in a paint roller manufacturing processaccording to claim 12, wherein the filler comprises calcium carbonate.14. The method for using a perforated fabric in a paint rollermanufacturing process according to claim 13, wherein the resin comprises10-66% CaCO3 by weight.
 15. The method for using a perforated fabric ina paint roller manufacturing process according to claim 14, wherein apolypropylene used in the resin has a melt flow rate that ranges from900 to 1300 g/10 min.
 16. The method for using a perforated fabric in apaint roller manufacturing process according to claim 1, wherein thestep of using a fabric-coating applicator to apply a fabric adhesive isperformed offline from the paint roller manufacturing process.
 17. Themethod for using a perforated fabric in a paint roller manufacturingprocess according to claim 1, wherein the step of using a fabric-coatingapplicator to apply a fabric adhesive is performed online with the paintroller manufacturing process.
 18. The method for using a perforatedfabric in a paint roller manufacturing process according to claim 1,wherein the perforated fabric has a backing with a thickness of 0.30inches to 0.50 inches.
 19. The method for using a perforated fabric in apaint roller manufacturing process according to claim 18, wherein thestep of using a fabric-coating applicator yields a coated fabric havingan adhesive that has penetrated to a depth of not more than thethickness of the fabric backing.
 20. The method for using a perforatedfabric in a paint roller manufacturing process according to claim 1,wherein fabric adhesive comprises a compounded polypropylene resinhaving an effective melt flow rate of 100-400 g/10 min.
 21. The methodfor using a perforated fabric in a paint roller manufacturing processaccording to claim 1, wherein fabric adhesive comprises a compoundedpolypropylene resin having an effective melt flow rate of 120-220 g/10min.
 22. The method for using a perforated fabric in a paint rollermanufacturing process according to claim 1, wherein fabric adhesivecomprises a compounded polypropylene resin having an effective melt flowrate of 130-180 g/10 min.
 23. The method for using a perforated fabricin a paint roller manufacturing process according to claim 1, whereinfabric adhesive comprises an uncompounded polypropylene resin having aneffective melt flow rate of 20-140 g/10 min.
 24. The method for using aperforated fabric in a paint roller manufacturing process according toclaim 1, wherein fabric adhesive comprises a compounded polypropyleneresin, compounded with greater than 50% filler by weight, having aneffective melt flow rate of 140-400 g/10 min.
 25. A method for using aperforated fabric in a manufacturing process, comprising: winding aninner strip and an outer strip about a mandrel in offset relation;receiving a portion of a heat-perforated paint roller fabric material,having a plurality of perforations through which adhesive may flow, atthe outer strip and winding the length of heat-perforated fabric aboutat least the outer strip to form a paint roller tube; applying anadhesive onto a portion of the paint roller cover fabric material, andinto the plurality of perforations and into interstitial spaces of thefabric material; applying the adhesive onto at least a portion of theouter strip as it is wound about the mandrel; applying compression tothe paint roller tube; and, cutting the paint roller tube into likelengths. 26-30. (canceled)
 31. An inline paint roller cover materialmanufacturing method for a paint roller manufacturing system having amandrel, a strip dispenser for continuously dispensing a windable widthof strip material having an inner side and an outer side, a guide systemfor guiding the windable strip coming from the strip dispenser to bewound about the mandrel, an adhesive applicator configured to applyadhesive on substantially all of the outer side of the windable stripupstream of a location where a paint roller cover is wound about thewindable strip, and a paint roller cover material feeder forcontinuously feeding a windable width of paint roller cover material,the paint roller cover material having a back side and an applicatorside, a compressing and advancing device for applying inward pressurenormal to the mandrel on the paint roller cover material after it iswound about the strip, and for advancing the adhesive-coated windablestrip and the paint roller cover material along the mandrel, the inlinepaint roller cover material manufacturing system comprising: perforatinga paint roller cover fabric material with a heated perforator to producea perforated paint roller cover fabric material; feeding a windablewidth of perforated paint roller cover fabric, the paint roller coverfabric having a back side and an applicator side; applying a coating tothe back side of the perforated paint roller cover fabric and into theplurality of perforations and into interstitial spaces of the fabricmaterial; applying, downstream of the applying step, a compressive forceon the coating after it has been applied to the back side of theperforated paint roller cover fabric, thereby forming a paint rollercover material.